2004 Chevrolet Malibu
Safety Recalls & Notices
We found 21 safety recalls for the 2004 Chevrolet Malibu. Recalls are sourced from both NHTSA (US) and Transport Canada databases. Contact your authorized Chevrolet dealer to schedule free repairs.
Summary
On certain vehicles, a defect in the ignition switch could allow the switch to move out of the "run" position if the key ring is carrying added weight or the vehicle goes off-road or is subjected to some other jarring event. If this were to occur, engine power, power steering and power braking would be affected, increasing the risk of a crash causing injury and/or damage to property. The timing of the key movement out of the “run” position, relative to the activation of the sensing algorithm of the crash event, may also result in the airbags not deploying in a subsequent collision, increasing the risk of injury. Correction: For each key, dealers will install two key rings and modify the key ring opening shape. Note: Until the correction is performed, all items should be removed from the key ring.
Summary
On certain vehicles, intermittent electrical connection faults may cause the brake lamps to illuminate without the brake pedal being depressed, or not illuminate when the brake pedal is depressed. This could also interfere with cruise control, ABS and/or vehicle stability control function. Failure of the brake lights to illuminate when the brake pedal is depressed or erratic brake lamp function could increase the risk of a crash causing property damage and/or personal injury. Correction: Dealers will affect repairs.
Summary
On certain vehicles equipped with 4 speed automatic transmissions, the shift cable could fracture without warning. If this occurs, the driver may not be able to select a different gear position, remove the key from the ignition, or place the transmission in the PARK position. If the driver cannot place the vehicle in the PARK position and exits the vehicle without applying the parking brake, the vehicle could roll away, which could result in a crash causing injury and/or damage to property. Correction: Dealers will install a revised shift cable and mounting bracket.
Summary
Certain vehicles equipped with electric power steering may experience a sudden loss of power steering assist that could occur at any time while driving. If the power steering assist is lost, a message is displayed on the Driver Information Centre and a chime sounds to inform the driver. Steering control can be maintained, as the vehicle will revert to a manual steering mode, but will require greater driver effort. The sudden change in steering may increase the risk of a crash causing injury and/or property damage. Correction: Dealers will affect repairs as necessary. Note: This recall supersedes recalls 2010447 and 2012331. Vehicles having already been repaired under the previous campaigns do not require re-inspection.
Summary
On certain vehicles, the Electronic Control Unit (ECU) may calculate a higher than actual vehicle speed because of an erratic rear-wheel speed sensor signal, and cause ABS activation where it is not needed or needed ABS activation to be extended during braking as the vehicle speed drops to about 5km/h. A four-wheel ABS activation could occur for a maximum of 1.25 seconds on a level surface or for up to 2.5 seconds if the vehicle is on a grade, resulting in increased stopping distances of up to 3.4m. Correction: Dealers will reprogram the ABS controller.
Summary
On certain vehicles, analysis of a side impact test indicated the outboard anchorage of the driver's seat belt could disconnect because of contact between the seat trim and the anchorage connector when the seat was adjusted to its lowest position. If this occurred in a crash, the driver could receive greater injuries. Correction: Dealer will install a retainer between the latch spring and the latch spring guard on the anchorage - driver and passenger side.
Summary
Certain vehicles that are not equipped with an Advanced Occupant Restraint System (AORS) have driver and passenger side sun visors with AORS labels. The AORS labels do not include statements and illustration required by CMVSS 208 for vehicles without AORS. Correction: Dealer will send replacement labels to owners with instructions on how to install them.
Summary
Dorman Products, Inc. (Dorman) is recalling certain replacement intermediate steering shafts sold under the Dorman, OE Solutions, and Solutions brand names, part numbers 425-167, 2425167, and 7-3074, for installation on 2004-2012 Chevrolet Malibu, 2005-2010 Pontiac G6, and 2007-2009 Saturn Aura vehicles. The affected steering shafts may have a yoke that inadequately supports the u-joint bearing resulting in a premature failure.
Potential Consequence
A joint bearing that fails prematurely may cause separation of the u-joint resulting in a complete loss of steering control, increasing the risk of a crash.
Remedy
Dorman will notify owners, and dealers will refund the purchase price or replace the steering shafts, free of charge. The recall began in September 2014. Owners may contact Dorman customer service at 1-800-523-2492.
Summary
General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April 5, 2007, 2005-2010 Pontiac G6 vehicles manufactured May 26, 2004, through January 4, 2010, and 2007-2010 Saturn Aura vehicles manufactured April 24, 2006, through May 26, 2009. In the affected vehicles, increased resistance in the Body Control Module (BCM) connection may result in voltage fluctuations in the Brake Apply Sensor (BAS) circuit. These fluctuations can cause one or more of these conditions: the brake lights to illuminate without the brake pedal being pushed; the brake lights to not illuminate when the pedal is pushed; difficulty disengaging the cruise control; moving the gear shifter out of the 'PARK' position without pushing the brake; and disablement of crash avoidance features such as traction control, electronic stability control, and panic braking assist features.
Potential Consequence
Any of the above failure conditions increases the risk of a crash.
Remedy
GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and harness connector, and will relearn the brake pedal home position, free of charge. The manufacturer distributed an Interim letter to customers on July 14, 2014. The recall began on August 18, 2014. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet), 1-800-762-2737 (Pontiac), 1-800-553-6000 (Saturn). GM's number for this recall is 13036.
Summary
General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April 5, 2007, 2005-2010 Pontiac G6 vehicles manufactured May 26, 2004, through January 4, 2010, and 2007-2010 Saturn Aura vehicles manufactured April 24, 2006, through May 26, 2009. In the affected vehicles, increased resistance in the Body Control Module (BCM) connection may result in voltage fluctuations in the Brake Apply Sensor (BAS) circuit. These fluctuations can cause one or more of these conditions: the brake lights to illuminate without the brake pedal being pushed; the brake lights to not illuminate when the pedal is pushed; difficulty disengaging the cruise control; moving the gear shifter out of the 'PARK' position without pushing the brake; and disablement of crash avoidance features such as traction control, electronic stability control, and panic braking assist features.
Potential Consequence
Any of the above failure conditions increases the risk of a crash.
Remedy
GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and harness connector, and will relearn the brake pedal home position, free of charge. The manufacturer distributed an Interim letter to customers on July 14, 2014. The recall began on August 18, 2014. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet), 1-800-762-2737 (Pontiac), 1-800-553-6000 (Saturn). GM's number for this recall is 13036.
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